Advanced Thermoforming, 2nd Edition

Advanced Thermoforming, 2nd Edition

by Sven Engelmann
Released August 2023
Publisher(s): Wiley
ISBN: 9781119666059

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Book description

ADVANCED THERMOFORMING

Overview of advanced technologies in thermoforming including forming, filling, and sealing processes, and practical applications in various industries

Advanced Thermoforming offers an overview of and new insights into thermoforming by comparing current and new standards for forming and mold technologies, presenting concepts from the practitioner’s perspective in a case-study format showing the possibilities of automated processes, reviewing the forming, filling, sealing processes, and applications of technical parts and packaging.

The reader is guided along the path of design and development for machine and mold technologies and production processes. Along with updated content, this revised Second Edition adds new coverage of sustainability in packaging, circular economy principles, mold technology, electromotive applications, and developments in new polymeric materials. The text opens thermoforming to new applications and demands on plastic parts by covering advances in thermoforming machines, molds, and automation.

Advanced Thermoforming covers topics such as:

  • Basics of thermoforming and thermoplastics, production of semifinished products, extrusion, and coextrusion
  • Introduction to both heavy and thin gauge thermoforming
  • New approaches for more sustainable rigid packaging through thermoforming
  • Fuel tank production on sheet machines, automotive body and commercial vehicle applications, and production of refrigerator liners
  • Sustainability and circular economy principles in thermoforming

Presenting an impressive variety of advanced thermoforming technologies in a very readable form, Advanced Thermoforming is an essential reference for polymer and plastics engineers as well asprocessors, technical engineers, R & D managers, new product development managers, automotive engineers, technicians, and equipment designers.

Table of contents

  1. Cover
  2. Table of Contents
  3. Title Page
  4. Copyright Page
  5. Dedication Page
  6. Foreword
  7. Preface to Second Edition
  8. Preface to First Edition
  9. Introduction to Second Edition
  10. Chapter 1: Introduction
  11. Chapter 2: Basics of Thermoforming and Thermoplastics
    1. 2.1 THERMOFORMING METHODS
    2. 2.2 POSITIVE FORMING
    3. 2.3 NEGATIVE FORMING
    4. 2.4 ADVANTAGES AND DISADVANTAGES OF THERMOFORMING
    5. 2.5 THERMOFORMING MACHINES
    6. 2.6 SEMIFINISHED THERMOPLASTIC PRODUCTS
  12. Chapter 3: Production of Semifinished Products, Extrusion, and Coextrusion
    1. 3.1 EXTRUSION
    2. 3.2 COEXTRUSION
  13. Chapter 4: Introduction to Technical Parts
  14. Chapter 5: Antenna Radome Manufacturing
    1. 5.1 WEATHER‐RESISTANT HIGH‐IMPACT POLYSTYRENE
    2. 5.2 THE EFFECT OF UV LIGHT
    3. 5.3 WETTING RESISTANCE
    4. 5.4 ANTENNA GAIN
    5. 5.5 WATER AND ANTENNA GAIN
  15. Chapter 6: Fuel Tank Production on Sheet Machines
  16. Chapter 7: Automotive Body and Commercial Vehicle Applications
    1. 7.1 APPLICATIONS FOR CAR BODIES—ABS/PMMA
    2. 7.2 CAR BODIES FOR UTILITY VEHICLES
    3. 7.3 COVER FOR HEAD LAMP
  17. Chapter 8: Production of Refrigerator Liners
    1. 8.1 HIGH‐IMPACT POLYSTYRENE (PS‐HI)
    2. 8.2 SYNTHESIS
    3. 8.3 MORPHOLOGY
    4. 8.4 MECHANISM OF RUBBER REINFORCEMENT
    5. 8.5 PROPERTIES OF PS‐HI
    6. 8.6 RUBBER‐MODIFIED SAN COPOLYMERS (ABS)
    7. 8.7 GENERAL GRADES OF ABS
    8. 8.8 THE THERMOFORMING PRODUCTION PROCESS
    9. 8.9 ENVIRONMENTAL STRESS CRACKING
    10. 8.10 REFRIGERATOR OUTSIDE COVERS
  18. Chapter 9: Paint Replacement in Automotive Applications
    1. 9.1 PAINT REPLACEMENT
    2. 9.2 REASONS FOR REPLACEMENT OF PAINT IN AUTOMOTIVE APPLICATIONS
    3. 9.3 LAYER CONSTRUCTION OF COEXTRUDED INLINE COLORED PLASTIC SHEETS
    4. 9.4 COLOR MANAGEMENT DURING PRODUCT DEVELOPMENT AND PRODUCTION
    5. 9.5 REQUIREMENTS FROM THE AUTOMOTIVE INDUSTRY ON SURFACE QUALITY
    6. 9.6 REQUIREMENTS FROM THE AUTOMOTIVE INDUSTRY ON COLOR MATCH
    7. 9.7 AUTOMOTIVE INDUSTRY AND “ORANGE PEEL”
    8. 9.8 EXAMPLES OF PAINT REPLACEMENT IN AUTOMOTIVE APPLICATIONS
    9. 9.9 PAINT‐FILM TECHNOLOGY: PAINTING PRIOR TO THERMOFORMING
  19. Chapter 10: Motor Air Intake Made from PA 6 GF 15
  20. Chapter 11: Sanitary Equipment (Sheet Machine)
    1. 11.1 FROM THE RIG TO THE THERMOFORMING MACHINE
    2. 11.2 FINISHING
    3. 11.3 REINFORCEMENT METHODS FOR BATHTUBS
  21. Chapter 12: Thermoforming and Milling of Large‐Scale Formed Parts (Sheet Machine)
    1. 12.1 SURFACE PROBLEMS
    2. 12.2 MOLD SHRINKING AND FREE SHRINKAGE
    3. 12.3 EXPANSION
    4. 12.4 THE DECISION BETWEEN POSITIVE OR NEGATIVE FORMING
    5. 12.5 TWIN‐SHEET FORMING
    6. 12.6 AUTOMATION
  22. Chapter 13: Changeover of Sheet Machines
    1. 13.1 THE INCREASING IMPORTANCE OF THE CHANGEOVER PROCEDURE
    2. 13.2 SHORTENING OF CHANGEOVER WITH HIGH‐QUALITY EQUIPMENT
  23. Chapter 14: Chromed Parts
  24. Chapter 15: Applications in Aircraft and Mass Transportation
    1. 15.1 CURRENT GOVERNMENT AND OEM SPECIFICATIONS FOR FLAMMABILITY
    2. 15.2 USE OF ACRYL/PVC
    3. 15.3 POLYCARBONATE
    4. 15.4 POLYETHERIMIDE (PEI)
    5. 15.5 POLYPHENYLSULFONE (PPSU)
  25. Chapter 16: High‐Quality and Fully Transparent Products (Sheet Machines)
    1. 16.1 THICK AND SELF‐SUPPORTING CLASS‐A FORMED PARTS
    2. 16.2 CLASS‐A MOLDED PARTS FOR IN‐MOLD DECORATION
    3. 16.3 DEVELOPMENT OF FULLY TRANSPARENT PRODUCTS
  26. Chapter 17: Deco Molding and Multi‐deco Molding
    1. 17.1 THERMOFORMING
    2. 17.2 INJECTION MOLDING
    3. 17.3 TACTILE EFFECTS
    4. 17.4 OTHER SECTOR PARTS
    5. 17.5 MULTI‐DECO MOLDING
    6. 17.6 THE AUTOMATED SEQUENCE PROCESS
  27. Chapter 18: Smart Manufacturing
    1. 18.1 TRANSATLANTIC COOPERATION
    2. 18.2 DESIGN OF EXPERIMENT
    3. 18.3 CONCLUSION
    4. 18.4 REMOTE THERMOFORMING LINE COMMISSIONING AND REMOTE SERVICE SUPPORT
  28. Chapter 19: Automotive Body Parts Made of PA + ABS
  29. Chapter 20: Softfeel Made from ABS/ TPU Material
  30. Chapter 21: Introduction to Packaging
  31. Chapter 22: Optimizing a Thermoforming Process for Packaging
    1. 22.1 METHOD FOR OPTIMIZING A PROCESS TO PRODUCE A THERMOFORMED ARTICLE FROM POLYMERIC MATERIAL
    2. 22.2 CHARACTERIZATION OF RESINS BY PERFORMANCE PARAMETERS
    3. 22.3 VARIABLES THAT CAN BE ALTERED TO INFLUENCE THE PLUG FORCE AND CAVITY PRESSURE
    4. 22.4 APPLICATION EXAMPLES
  32. Chapter 23: Analysis of Thermoforming Films
    1. 23.1 GENERAL ANALYSIS OF THERMOFORMING FILMS
    2. 23.2 TESTS MEASURING FREE SHRINKAGE
    3. 23.3 TESTS MEASURING THICKNESS
    4. 23.4 TENSILE STRENGTH TEST
    5. 23.5 SURFACE TEXTURE TEST FOR THE GLOSS FACTOR
    6. 23.6 FLAME COLORATION
  33. Chapter 24: Advanced Analysis of Thermoforming Films
    1. 24.1 PRODUCT QUALITY DEMANDS
    2. 24.2 DIFFERENTIAL SCANNING CALORIMETRY
    3. 24.3 DMA (DYNAMIC MECHANICAL ANALYSIS)
    4. 24.4 TORSION PENDULUM TEST
    5. 24.5 SUMMARY
  34. Chapter 25: Analysis of Thermoformed Products
    1. 25.1 WALL THICKNESS DISTRIBUTION
    2. 25.2 TOP LOAD
    3. 25.3 VISUAL APPEARANCE
    4. 25.4 WATER VAPOR PERMEABILITY
    5. 25.5 OXYGEN PERMEABILITY
    6. 25.6 TRANSPARENCY
    7. 25.7 TESTING DEVICE FOR THE PRACTICAL ASSESSMENT OF THERMOFORMABILITY
  35. Chapter 26: Analysis of Completely Formed, Filled, and Sealed Containers
    1. 26.1 BURST PRESSURE AND IMPERMEABILITY
    2. 26.2 RHODAMINE TEST
    3. 26.3 GENERAL REMARK ON IMPERMEABILITY TESTS
    4. 26.4 OPENING FORCE
  36. Chapter 27: Automated Packaging
    1. 27.1 CUTTING SUBSEQUENT TO FORMING
    2. 27.2 CHARACTERISTICS OF THERMOFORMING PACKAGING LINES
    3. 27.3 CHARACTERISTICS OF PACKAGING MACHINE CONTROL
    4. 27.4 FORMING, FILLING, AND SEALING (FFS)
    5. 27.5 FORMING, PUNCHING, FILLING, AND SEALING (FPF)
    6. 27.6 FORMING, CROSS‐CUTTING, FILLING, SEALING/PUNCHING (FCFS)
    7. 27.7 CONCLUSION
  37. Chapter 28: Production of Flowerpots
    1. 28.1 THE THERMOFORMING MACHINE
    2. 28.2 HEATING SYSTEM
    3. 28.3 THE FORMING STATION
    4. 28.4 FORMING AIR
    5. 28.5 CHALK AS A FILLER
  38. Chapter 29: Perforated Fruit and Vegetable Trays Made Easy
  39. Chapter 30: Steel Rule Die Punching
    1. 30.1 BASICS
    2. 30.2 SHAPES OF CUTTING EDGES
    3. 30.3 CREATION OF ANGEL HAIR DURING STEEL RULE DIE CUTTING
  40. Chapter 31: Production of Meat Trays
    1. 31.1 VACUUM PACKAGING
    2. 31.2 ACTIVE PACKAGING
    3. 31.3 MAP
    4. 31.4 PRODUCTION PROCESS FOR THE PP TRAY
    5. 31.5 NEW DEVELOPMENTS
  41. Chapter 32: Multilayer Films for Thermoforming Applications
  42. Chapter 33: PET in Thermoforming Applications
    1. 33.1 EXTRUSION AND THERMOFORMING OF A‐PET RESINS
    2. 33.2 PET FOR ELECTRONIC PACKAGING
    3. 33.3 PET‐G (GLYCOL‐MODIFIED POLYETHYLENE TEREPHTHALATE)
    4. 33.4 SLIP AND ANTIBLOCK MASTERBATCHES
    5. 33.5 RECLAIMING SCRAP
  43. Chapter 34: Thermoformed Packaging Made of PLA
    1. 34.1 PHYSICAL PROPERTIES
    2. 34.2 COMPOSTABILITY
    3. 34.3 PROCESSING OF PLA FILM
    4. 34.4 THERMOFORMING OF PLA
    5. 34.5 FILM TRANSPORT
  44. Chapter 35: Peel and Reseal
    1. 35.1 FILM MATERIALS
    2. 35.2 PRODUCTION OF FILMS FOR PACKAGING
    3. 35.3 PRODUCTION OF RESEALABLE FOOD PACKAGING
    4. 35.4 PEEL AND RESEAL
  45. Chapter 36: Foam Packaging with PP and PS
    1. 36.1 POLYPROPYLENE
    2. 36.2 POLYSTYRENE
  46. Chapter 37: Blister Packaging of Syringes
    1. 37.1 A‐PET/PE
    2. 37.2 MATERIAL DESCRIPTION
    3. 37.3 THE MANUFACTURING PROCESS
    4. 37.4 SUMMARY OF THE PRODUCTION METHODS FOR A‐PET/PE FILMS
    5. 37.5 PRODUCTION OF BLISTERS IN THE PACKAGING LINE
  47. Chapter 38: The Production of Drinking Cups
    1. 38.1 FROM MONOMER TO POLYMER
    2. 38.2 MECHANICAL AND THERMAL BEHAVIOR OF PP
    3. 38.3 DIFFERENCE BETWEEN MOLD SHRINKAGE AND FREE SHRINKAGE
    4. 38.4 POLYPROPYLENE MODIFICATIONS
    5. 38.5 THERMOFORMING CONDITIONS AND FINISHED PART ATTRIBUTES
    6. 38.6 DISTRIBUTION OF MOLECULAR WEIGHT
    7. 38.7 INFLUENCE OF NUCLEATION OF PP ON PROCESSING AND CHARACTERISTICSOF THE FINISHED PART
    8. 38.8 HIGH CRYSTALLINE/HIGH STIFFNESS POLYPROPYLENE
    9. 38.9 INFLUENCE OF FILM PRODUCTION TECHNOLOGY
    10. 38.10 OPTICAL PROPERTIES
    11. 38.11 FILM MORPHOLOGY
    12. 38.12 THE THERMOFORMING MACHINE
    13. 38.13 THE MOLD
    14. 38.14 STACKING
    15. 38.15 DOWNSTREAM DEVICES
  48. Chapter 39: Approaches for More Sustainable Rigid Packaging Through Thermoforming
    1. 39.1 TOOL LAYOUTS
    2. 39.2 FORMING STATION
    3. 39.3 PLUG ASSIST
    4. 39.4 ENERGY EFFICIENCY
    5. 39.5 FURTHER HIGHLIGHTS
    6. 39.6 TOOL CHANGE
    7. 39.7 DOWNSTREAM VARIANTS
    8. 39.8 TOOL
  49. Chapter 40: Mold Making for Thermoforming in Packaging
    1. 40.1 RIM ROLLING IN THERMOFORMING
  50. Chapter 41: Ultrasonic Sealing and Cutting in Thermoforming
    1. 41.1 BACKGROUND
    2. 41.2 DEVELOPMENT OF ULTRASONIC SEALING AND CUTTING TECHNOLOGY
    3. 41.3 CONCLUSIONS
  51. Chapter 42: Understanding the Brittle Behavior of Polystyrene Cups
    1. 42.1 EXPERIMENTAL METHODS
    2. 42.2 RESULTS AND DISCUSSION
    3. 42.3 CUP ORIENTATION RESULTS
    4. 42.4 CONCLUSION
    5. 42.5 APPENDIX: ORIENTATION IN VENDING CUPS
  52. Chapter 43: Preprinted Film for Lid Thermoforming
  53. Chapter 44: Flexible Films
    1. 44.1 FLEXIBLE PACKAGING MATERIAL
    2. 44.2 MAIN FLEXIBLE FILM TYPES
    3. 44.3 SEALING LAYERS
  54. Chapter 45: Simulation
    1. 45.1 T‐SIM COMPUTER SIMULATION OF THERMOFORMING
    2. 45.2 FEATURES OF SIMULATION SOFTWARE SUCH AS T‐SIM
    3. 45.3 PRE‐DISTORTION OF IMAGES
    4. 45.4 CAD FEASIBILITY STUDY
  55. Chapter 46: Sustainability and Circular Economy
    1. 46.1 EUROPE
    2. 46.2 USA
    3. 46.3 INTERNATIONAL
    4. 46.4 CHINA
    5. 46.5 POLYSTYRENE (PS)
    6. 46.6 POLYPROPYLENE (PP)
    7. 46.7 POLYETHYLENE TEREPHTHALATE (PET)
  56. Glossary
  57. Index
  58. End User License Agreement

Product information

  • Title: Advanced Thermoforming, 2nd Edition
  • Author(s): Sven Engelmann
  • Release date: August 2023
  • Publisher(s): Wiley
  • ISBN: 9781119666059